SUPPLEMENTAL MAINTENANCE MANUAL …

1 SUPPLEMENTAL MAINTENANCE MANUAL . instructions for continued Airworthiness AMSAFE AVIATION INFLATABLE RESTRAINT. (AAIR ) V23 SYSTEM. for Zenair CH2000 SERIES AIRCRAFT. SAA Series No. 7032. AMSAFE AVIATION Document Number E508449. PROPRIETARY NOTICE. This document and the information disclosed herein are the proprietary data of AMSAFE Aviation. Neither this document nor the information contained herein shall be used, reproduced, or disclosed to others without the written authorization of AMSAFE Aviation, except to the extent required for installation or MAINTENANCE of recipient's equipment.

2 NOTICE FREEDOM OF INFORMATION ACT (5 USC 552) AND DISCLOSURE OF CONFIDENTIAL INFORMATION. GENERALLY (18 USC 1905). AMSAFE Aviation is furnishing this document in confidence. The information disclosed herein falls within exemption (b). (4) of 5 USC 552 and the prohibitions of 18 USC 1905. The AMSAFE Aviation Commercial And Government Entity (CAGE) code: OFWE1. AAIR is a registered trademark of Am-Safe, Inc. All rights reserved. 5456 E. McDowell Rd., Mesa, AZ 85215 Phone: 480-344-4700 Fax: 480-344-4777 12-Jan-2004 Page i AMSAFE AVIATION.

3 AAIR SUPPLEMENTAL MAINTENANCE MANUAL E508449. TABLE OF CONTENTS. DESCRIPTION 1. SYSTEM OPERATION 1. SYSTEM COMPONENTS AND PARTS LIST 1. MAINTENANCE AND INSPECTION 4. MAINTENANCE 4. System Functional Testing 4. Inspection 4. Cleaning 4. STORAGE OF SPARES 5. Inflator Assembly 5. Electronics Module Assembly (EMA) 6. Seatbelt Airbag Assembly (SAA) 6. REMOVAL AND REPLACEMENT 6. Equipment and Materials Required 6. Removal 7. Replacement 9. AIRWORTHINESS LIMITATIONS 11. Inspection Intervals 11. Inoperable AAIR System 11.

4 Life Limits 11. Renewal 11. WARRANTY AND RETURN INFORMATION 12. RMA Procedures 12. Packaging and Shipping Requirements Inflation device 12. Packaging and Shipping Requirements AAIR Components except the Inflation device 13. REFERENCE PUBLICATIONS 13. TABLES. Table 1 - Torque Values and Tool Sizes 7. FIGURES. Figure 1 AAIR V23 System Components 2. Figure 2 Inflator Assy Shipping Cap 2. Figure 3 V23 System Diagnostic Tool, P/N 508668-201 3. Figure 4 Electrical and Hose Connectors of Inflator Assembly 7.

5 Figure 5 EMA Module and Cable Interface Assembly 8. Figure 6 EMA Aircraft Forward Installation 10. 12-Jan-2004 Page iii AMSAFE AVIATION. AAIR SUPPLEMENTAL MAINTENANCE MANUAL E508449. INTRODUCTION. DESCRIPTION. This MANUAL contains service and MAINTENANCE instructions for the AMSAFE Aviation Inflatable Restraint (AAIR ), V23 Version, installed on the Zenair CH2000 aircraft. The AAIR V23 is a self- contained, modular, three-point restraint system that improves protection from serious head- impact injury during a survivable aircraft crash.

6 SYSTEM OPERATION. Within milliseconds of an injurious crash event, the EMA's crash sensor evaluates the crash pulse and then sends a crash pulse signal throughout the activation circuit. This signal releases the gas in the inflator, rapidly inflating the airbag within the airbag belt's cover breaking through the cover's tearable seam, and filling the airbag to its fully-inflated state. The inflating airbag will automatically position itself between the cockpit controls and the pilot/co-pilot thus providing head protection during the most critical time of the event.

7 After airbag deployment, the airbag deflates to enable the pilot/co-pilot to egress the aircraft without obstruction from the airbag. The crash sensor's predetermined deployment threshold does not allow inadvertent deployment during normal operations, such as hard landings, strikes on the seat, random vibration, or windmilling conditions. To activate the system, join (buckle) the three-point restraint in the same manner as any other three-point seatbelt. SYSTEM COMPONENTS AND PARTS LIST. The AAIR V23 System consists of these core components: Seatbelt Airbag Assembly (SAA) 1 per seat position; 2 per aircraft Inflation Assembly 1 per seat position; 2 per aircraft Electronics Module Assembly (EMA) 1 per aircraft Cable Interface Assembly 1 per aircraft The SAA (1A, 1B) consists of two primary subassemblies; the Three-Point Airbag Belt Assy (10A, 10B) with Safety Cable Tie (11) and the End-Release Buckle Assy (20A, 20B) (see Figure 1).

8 The SAA mounts to aircraft structure using existing mounting points. The Inflator Assembly (30) (Figure 1) mounts behind the lower back of each seat. The Inflator Shipping Cap (31) makes the inflator a thrust-neutral device and is to be used whenever the inflator is shipped as a non-installed item. The End-Release Buckle Assy provides the electrical connector to the Inflator Assy to complete the activation circuit. The Cable Interface Assy (40) connects the EMA (50) to the two SAAs and also provides a Diagnostic Tool Connector leg (see Figure 1).

9 The Diagnostic Tool Connector leg connects to the System Diagnostic Tool to facilitate system functional checks. The EMA, which contains the system electronics and system power (Lithium-type battery), is mounted to aircraft structure in the center console area. 12-Jan-2004 Page 1. AMSAFE AVIATION. AAIR SUPPLEMENTAL MAINTENANCE MANUAL E508449. SAA 1A, 1B. Consists of 10A, EMA. B and 20A, B 50. Diagnostic Inertia Reel Connector Leg EMA. Connector Cable Interface Assembly 40. Three-Point Airbag Assy - 10A, 10B.

10 Gas Hose Inflator Assembly 30. Inflator Electrical Connection End-Release (SAA) Connector SAA Connectors to Cable Interface Assy End-Release Buckle Assy - Figure 1 AAIR V23 System Components 20A, 20B. Inflator Hose Fitting Inflator Shipping Cap - 31. Figure 2 Inflator Assy Shipping Cap 12-Jan-2004 Page 2. AMSAFE AVIATION. AAIR SUPPLEMENTAL MAINTENANCE MANUAL E508449. SDT. 60. Figure 3 V23 System Diagnostic Tool, P/N 508668-201. Qty per System 508504-201-2396. Item Used Fig. No. Part Number Part Description No.